Throughout Australia, waste disposal sites are critical infrastructure for managing the byproducts of human activity. These facilities must endure harsh conditions, including heavy machinery traffic and exposure to various chemicals and leachate. One of the key elements in maintaining the safety, functionality and integrity of the concrete substrate on these sites is the use of purpose-designed floor toppings. Floor toppings provide a protective layer that enhances durability, reduces maintenance costs, and extends the lifespan of the asset. It is essential to understand the specific requirements and uses of each facility to choose the appropriate floor topping. Factors such as the type of waste, traffic load, and chemical exposure must be considered. Australasian Specialty Coatings (ASC) is a flooring and protective coatings company that specialises in servicing the waste and water industry.
It is essential to understand the specific requirements and uses of each facility to choose the appropriate floor topping. Factors such as the type of waste, traffic load, and chemical exposure must be considered.
Australasian Specialty Coatings (ASC) is a flooring and protective coatings company that specialises in servicing the waste and water industry. It is often asked to assess the condition of the tipping floor sheds whereby the reinforced steel has started to pertrude from years of wear and tear. As is common with putrescible waste tipping floors, the top layer of the concrete floor is often eroded from a mixture of heavy machinery movements and the corrosive effect from leachate reacting with the concrete slab.
ASC’s clients range from large multinational waste companies to municipal councils and private businesses and often have 24-hour, seven-day-a-week collections and tipping.
The company understands there needs to be a fast turnaround solution that will have minimal impact on the daily operation to these critical sites in handling Australia’s constant waste stream.
Traditionally, sites have had to be closed while concrete rectification (pouring a new slab) was undertaken. The problem with that was that the new concrete had to cure up to 28 days and was still not chemically resistant to leachate.
ASC has designed a chemical-resistant wear coat that can be installed over a weekend (up to 500 sqm), which means a site does not have to close down. With planning between ASC and the client, normal operations can continue while rectification work is completed.
After the relevant paperwork and safety briefings, the job usually starts with the worksite being excluded with bollards and the slab being washed down then dried overnight with fans. Early the next morning ASC starts the preparation and installation process by first abrasive blasting the slab to remove any trapped waste, and provide the correct key for the upcoming surface installation.
Once the surface has been correctly prepared, the next step is to treat cracks and spalling in the floor with resin injections to seal and bridge the weakest points.
The next stage is to coat the area with an acid-resistant primer, which can be coloured so in the future wear patterns are clearly visible and repaired accordingly. Once the primer has started its chemical reaction, ASC then starts to place the TUFF COAT screed over the surface. This can be varied in thickness but typical floors with 200,000 tonnes per year require approximately 20mm. The screed coat is left to cure for more than eight hours over night. The next day a skim coat is placed over the surface and aggregates laid in the skim coat to assist the wheels of the machinery.
The area is completely chemically cured and is ready to go back into action. The process has minimal down time and delivers a brand-new leachate-resistant floor that allows client to carry on with their operations with minimal fuss.
ASC’s managing director Louis Longhi explains that floor toppings are an essential component in the maintenance and longevity of waste disposal sites by providing a barrier between the concrete substrate and protecting against abrasion and chemical attacks.
“We build long term relationships with our clients to understand their individual sites and operations ensuring once the initial floor is laid,” he said. “We monitor the condition for ongoing wear and tear.”